Valve Job - Complete

Complete valve job including cylinder head removal, valve grinding/lapping, valve guide and seat service, and reassembly with new seals and gaskets.

Warnings

Tools required

Parts

• Cylinder head gasket × 1 — Use OEM specification
• Valve cover gasket with grommets × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Valve stem seals (intake and exhaust) × 16 — Use OEM specification
• Intake manifold gasket × 1 — Use OEM specification
• Exhaust manifold gasket × 1 — Use OEM specification
• Cylinder head bolts (TTY) × 10 — Use OEM specification
• Camshaft cap bolt set × 16 — Use OEM specification
• Timing chain tensioner × 1 — Use OEM specification
• VVT-i oil control valve O-ring × 1 — Use OEM specification
• Spark plug tube seals × 4 — Use OEM specification
• Engine coolant × 1 — Toyota Super Long Life Pink
• Engine oil and filter × 1 — 0W-20
• RTV silicone gasket maker × 1 — Toyota 00295-00102 or equivalent
• Anti-seize compound × 1 — Use OEM specification

Fluids

• Toyota Genuine 0W-20 — 5 qt
• Toyota Super Long Life Coolant (Pink) — 10 qt

Preparation

1. Disconnect negative battery cable and wait 90 seconds for airbag system discharge
2. Drain engine coolant completely from radiator drain and block drain plugs
3. Drain engine oil and remove oil filter
4. Remove engine cover and air intake assembly
5. Remove ignition coils and spark plugs, noting cylinder positions
6. Support engine with hoist or fixture from above using lifting eyes
7. Remove right-side engine mount to allow access
8. Tag and disconnect all vacuum lines, electrical connectors, and fuel lines from cylinder head
9. Relieve fuel system pressure before disconnecting fuel lines
10. Photograph or diagram all wiring and hose routing for reassembly reference

Procedure

1. 1

   Remove intake and exhaust manifolds
   Disconnect throttle body and all intake components. Remove intake manifold bolts and separate manifold with gasket. Disconnect exhaust manifold from catalytic converter. Remove exhaust manifold nuts working from hot center section to cold outer sections. Keep all hardware organized by component.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
2. 2

   Remove valve cover and accessory components
   Remove PCV hoses and any remaining connectors from valve cover. Remove valve cover bolts in reverse of tightening sequence (outside to inside). Carefully separate valve cover and gasket. Remove VVT-i oil control valve from front of cylinder head. Remove any remaining sensors or brackets attached to cylinder head.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)

   Sensor Bolts11 Nm (8 lb-ft)
3. 3

   Set engine to TDC and remove timing components
   Rotate crankshaft clockwise to TDC of cylinder 1 (compression stroke). Verify timing marks on camshaft sprockets align with marks on timing cover. Mark timing chain position relative to camshaft sprockets with paint pen. Remove timing chain tensioner bolt and extract tensioner assembly. Use camshaft holding wrench on 24mm hex of exhaust camshaft and remove camshaft sprocket bolt. Remove intake camshaft sprocket bolt using same method. Carefully remove both sprockets while supporting timing chain. Secure timing chain with wire to prevent it falling into timing cover.
   ⚠Do not allow timing chain to fall into timing cover. Use wire or zip ties to suspend chain in position.
   Torque spec

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

   Camshaft Sprocket Bolt80 Nm (59 lb-ft)
4. 4

   Remove camshafts and rocker arms
   Loosen camshaft cap bolts in multiple passes working from outer caps toward center, reversing the tightening sequence. Remove all camshaft caps keeping them in exact order (they are marked with numbers and arrows). Lift out intake and exhaust camshafts carefully. Remove rocker arms and lash adjusters, organizing them by cylinder position for reinstallation in same locations. Inspect camshaft lobes and journals for scoring or excessive wear.
   Torque spec

   Camshaft Cap Bolts14 Nm (10 lb-ft)
5. 5

   Remove cylinder head
   Loosen cylinder head bolts in reverse of tightening sequence (from outside inward in specified pattern) using multiple passes. Remove all 10 head bolts and discard them. Carefully lift cylinder head off engine block using proper lifting points. If head is stuck, gently tap with plastic mallet on casting protrusions only, never on machined surfaces. Place cylinder head on clean wooden blocks with combustion chambers facing up.
   ⚠Cylinder head weighs approximately 40 lbs. Use proper lifting technique or get assistance.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
6. 6

   Disassemble valvetrain components
   Using valve spring compressor, compress each valve spring and remove keepers. Release compressor and remove valve spring retainer, valve spring, and spring seat. Remove valve from combustion chamber side. Keep all valves in order by cylinder and position (intake vs exhaust). Remove old valve stem seals from guides. Clean all carbon deposits from valve stems and combustion chambers using appropriate solvent and brushes.
   ⚠Valve spring compressor must be properly seated on retainer. Spring can release with significant force if tool slips.
7. 7

   Inspect cylinder head and measure components
   Clean cylinder head deck surface thoroughly. Using straight edge and feeler gauges, check cylinder head for warpage across length, width, and diagonally. Maximum warpage is 0.05mm (0.002 in). If beyond limit, head must be resurfaced by machine shop (maximum 0.20mm total material removal). Measure valve stem diameter and valve guide inside diameter with micrometer and bore gauge. Calculate stem-to-guide clearance. Intake clearance limit: 0.05mm, Exhaust limit: 0.07mm. Guides exceeding limits must be replaced.
   ℹ️Record all measurements for reference and to verify specifications are within tolerance.
8. 8

   Service valve guides and seats
   If valve guides are worn beyond limits, drive out old guides from combustion chamber side using guide driver. Install new guides from camshaft side, driving to specified depth. Ream new guides to proper clearance. Inspect valve seats for pitting, burning, or excessive wear. Use valve seat cutter set or grinding stones to recut seats to three-angle specification (top cut, seat cut, throat cut). Intake seat width should be 1.0-1.3mm, exhaust 1.3-1.6mm. Clean all grinding debris thoroughly from ports and combustion chambers.
   ℹ️Valve seat work requires precision. Consider professional machine shop service if inexperienced with valve seat cutting.
9. 9

   Grind and lap valves
   Inspect each valve for burning, pitting, or bent stems. Replace damaged valves. Clean valve faces and grind on valve grinding machine to proper angle if necessary. Apply thin coat of valve lapping compound to valve seat. Insert valve into guide and use lapping tool to rotate valve back and forth against seat with light pressure. Continue until consistent gray contact pattern appears on both valve and seat (approximately 1.5-2mm wide). Clean all lapping compound residue thoroughly with solvent. Apply Prussian blue to valve face, insert valve, rotate lightly, and check contact pattern. Pattern should be even and centered on seat width.
   ⚠All lapping compound must be completely removed before assembly. Residual compound will cause rapid wear.
10. 10

    Reassemble valvetrain in cylinder head
    Lubricate valve stems with clean engine oil. Install new valve stem seals on guides using seal installer tool. Install valves into their original positions. Install valve spring seat, valve spring (closer wound coils toward head), and retainer. Compress spring with valve spring compressor and install keepers in valve stem groove. Release compressor slowly and verify keepers are properly seated. Tap valve stem lightly with plastic mallet to ensure keepers are locked in place. Repeat for all 16 valves.
    ℹ️Valve springs are directional. Install with tighter wound coils or paint mark toward cylinder head.
11. 11

    Install cylinder head on engine block
    Clean engine block deck surface thoroughly, removing all old gasket material. Verify block surface is clean and dry. Install new cylinder head gasket on block, aligning all dowel pins and oil/coolant passages. Carefully lower cylinder head onto block using lifting equipment. Install NEW cylinder head bolts (finger tight only). Following Toyota tightening sequence, torque all bolts to 65 Nm (48 lb-ft) in multiple passes. Then tighten each bolt an additional 90 degrees using torque angle gauge in sequence. Finally, tighten each bolt an additional 90 degrees (total 180 degrees beyond torque spec) in sequence.
    ⚠️Head bolts MUST be new TTY bolts. Follow precise tightening sequence and angle specifications to prevent head gasket failure.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
12. 12

    Install camshafts and rocker arms
    Lubricate all rocker arms and lash adjusters with clean engine oil. Install lash adjusters and rocker arms in their original positions. Apply clean engine oil to all camshaft journals. Position intake and exhaust camshafts in cylinder head with timing marks facing up. Ensure rocker arm rollers contact camshaft lobes properly. Apply light engine oil to camshaft cap sliding surfaces. Install camshaft caps in correct positions (numbered and marked with arrows pointing toward timing chain end). Install cap bolts finger tight. Tighten camshaft cap bolts in multiple passes starting from center caps and working outward to outer caps. Final torque: 14 Nm (10 lb-ft).
    ⚠Camshaft caps must be installed in correct positions and orientation. Arrows point toward timing chain. Forcing wrong cap will damage head.
    Torque spec

    Camshaft Cap Bolts14 Nm (10 lb-ft)
13. 13

    Install timing chain and components
    Verify crankshaft is still at TDC. Rotate camshafts so timing marks align with reference marks on head. Install camshaft sprockets onto camshafts while aligning timing chain marks made during disassembly. Hold exhaust camshaft with 24mm wrench and torque sprocket bolt to 80 Nm (59 lb-ft). Repeat for intake camshaft sprocket. Compress new timing chain tensioner using vise and install retaining pin to hold plunger compressed. Install tensioner and torque bolt to 25 Nm (18 lb-ft). Remove retaining pin to release tensioner. Verify all timing marks are properly aligned after tensioner is released.
    ⚠Verify timing marks multiple times before proceeding. Incorrect timing will cause severe engine damage.
    Torque spec

    Camshaft Sprocket Bolt80 Nm (59 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
14. 14

    Install valve cover and remaining components
    Install new VVT-i oil control valve O-ring and reinstall valve. Clean valve cover and mating surface thoroughly. Install new valve cover gasket and spark plug tube seals. Apply small bead of RTV silicone to corners where timing cover meets cylinder head. Install valve cover and tighten bolts in sequence from center outward to 10 Nm (7 lb-ft). Install new intake manifold gasket and reinstall intake manifold, torquing bolts to 25 Nm (18 lb-ft). Apply anti-seize to exhaust manifold stud threads. Install new exhaust manifold gasket and manifold, torquing nuts from center outward to 30 Nm (22 lb-ft).
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Sensor Bolts11 Nm (8 lb-ft)
15. 15

    Complete reassembly and fill fluids
    Reconnect all vacuum lines, electrical connectors, and fuel lines per original routing documentation. Install new spark plugs and ignition coils. Reinstall right-side engine mount and torque mounting bolts appropriately. Remove engine support. Reinstall air intake assembly and engine cover. Install new oil filter and fill engine with 5 quarts of Toyota 0W-20 engine oil. Close coolant drain plugs and fill cooling system with Toyota Super Long Life Pink coolant (approximately 10 quarts total). Reconnect negative battery cable.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)

Reassembly

1. Double-check all electrical connectors, vacuum lines, and hoses are properly connected and routed
2. Verify all bolts and fasteners have been installed and torqued to specification
3. Ensure no tools or rags remain in engine compartment
4. Check that all fluid drain plugs are tight and fluids are filled to proper levels

Verification

• Before starting engine, rotate crankshaft two complete revolutions by hand to verify no interference. Resistance indicates timing error or improper assembly
• Start engine and verify oil pressure light extinguishes within 5 seconds
• Allow engine to idle and monitor for abnormal noises, oil leaks, coolant leaks, or exhaust leaks
• Check for proper operation of VVT-i system and verify no check engine lights
• Perform cylinder leak-down test to verify valve seating. Each cylinder should show less than 10% leakage
• Road test vehicle under light load and verify smooth operation across RPM range
• Recheck all fluid levels after test drive and top off as necessary
• Inspect for any leaks after engine reaches operating temperature and cools down
• Reset ECU adaptation values if necessary using diagnostic scan tool

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